Heat exchanger of the plate type

ABSTRACT

A heat exchanger of a structurally self-supporting plate type and provided with an internal flow passage constrained between a first and a second plate and extending between an inlet and an outlet; The flow passage is subdivided in multiple generally parallelly directed longitudinally extending channels with the longitudinally extending channels having continuous joints formed by the two plates; The longitudinally extending channels have an arch-shaped cross-section and the arch-shape of the plates of the channels is in the same face direction orthogonal to the plates; The parallel running longitudinally extending channels include several laterally directed arches relative to their main axis in their longitudinal extension.

The present invention is a heat exchanger of a structurally self-supporting plate type provided with an internal fluid passage between a first and a second plate (2, 3) whereof at least the first of the plates (2) is arranged to be exposed to a warmer or colder medium.

BACKGROUND ART

Swedish patent SE 533035 shows a heat exchange element of the plate type, with an internal fluid flow passage comprising two plates between an inlet and an outlet, and an interior passage that forms an extension between the inlet and outlet, where the passage is constrained between two parallel plates that are formed by a self-supporting polymer material. The two plates are joined with a number of point weldings distributed over the fluid passage area. A disadvantage of the Swedish patent is that the point welding process results in a quite flat surface. Such a flat surface reflects sunlight from the plate, particularly when the angle of the sun is inclined. An inclined sun angle also provides a small exposed area and a large degree of reflection. Another disadvantage is that the point weldings easily detach when the fluid is pressurized, incurring delamination of the plates.

U.S. Pat. No. 4,473,066 to Clark describes a so-called sun energy collector which is a panel with several flow channels formed as a multi-layered corrugated panel with manifolds for inlet and outlet. The flow channels are stacked convex channels.

U.S. Pat. No. 4,858,594 to McCurdy describes a sun heating panel with a series of flow channels formed as a two-layer corrugated panel with manifolds for inlet and outlet, and wherein the flow channels in addition to provide convex channels in their cross-section also are provided with indentations in the channel walls in order to induce turbulence in the flow channels so as for bringing more of the liquid in contact with the sun exposed surfaces inner face.

U.S. Pat. No. 4,346,695 to Kitzmiller flow channels with convex channels in their cross sections, wherein the underlying and overlying plates are convex towards the same face direction of the base plane. The parts of the plates which are in the base plane are plane.

BRIEF SUMMARY OF THE INVENTION

The invention is a heat exchanger of a structurally self-supporting plate type and provided with an internal flow passage (6) constrained between a first and a second plate (2, 3) and extending between an inlet (4) and an outlet (5),

-   -   wherein the flow passage (6) is subdivided in multiple generally         parallelly directed longitudinally extending channels (7),     -   the longitudinally extending channels (7) having continuous         joints (8) formed between the two plates (2, 3),     -   the longitudinally extending channels (7) having an arch-shaped         cross-section,     -   wherein the arch-shape of said plates (2, 3) of said channels         (7) is in the same face direction orthogonal to the plates,     -   wherein the parallelly running longitudinally extending channels         (7) comprise several laterally directed arches relative to their         main axis in their longitudinal extension.

The arc-shape is preferably in the direction of the desired exposed face.

In an advantageous embodiment of the invention the exposed plate (2) is formed in a heat conductive material, which increases the efficiency if the heat exchanger is used e.g. as a “sunlight collector”.

In an advantageous embodiment of the invention the second pate (3) is thermally insulated to reduce heat loss if the heat exchanger should increase the temperature of the through flowing fluid, or to control the heat loss towards only one side of the heat exchanger, if it is a wall installed radiator for heating in a house.

ADVANTAGES OF THE INVENTION

An advantage of the crescent-shape of the cross-section of the channels (7) is that a ratio of exposed surface area to volume of contained liquid is high, thus it has a large exposed area relative to the weight. This is an advantage if the panel is to be mounted as roof panels on a roof to collect sunlight, or if mounted as ceiling panels without having to increase the dimensions of existing girders.

The feature that the generally parallelly running longitudinally extending channels (7) comprise several laterally directed arches kinked about 45 degrees relative to their main axis in their longitudinal extension, please see FIG. 4, will make the cross-section of one channel (7) in one section plane partially overlap a cross-section of another channel (7) in another section plane, thus increasing the panel's bending stiffness about the general longitudinal axis of the channels. Further, a kink angle of 45 degrees is a good compromise to allow several parallelly running channels.

In an embodiment of the invention the longitudinally extending channels (7) have a corrugated surface generally across the longitudinal direction. This create microturbulence in the through flowing fluid, which promotes heat transfer from the wall to the contained through flowing liquid or vice versa, which is an advantage.

The feature of the continuous joints (8) between those two plates (2, 3) forming a long zig-zag pattern at either sides of each channel (7) will result in a large joint area between the two plates (2, 3). This will allow a higher liquid pressure before delaminating than for the point-welded heat exchange element shown in SE 533035 wherein the two plates are joined with a number of point weldings distributed over the fluid passage area, which has a far lower welding area than for the present invention, and which may not withstand much liquid internal pressure.

The feature that in the cross-section of the channel (7) both the lower and the upper plate will form a bridge structure, and that the contained liquid sets up an internal liquid pressure between the upper and lower plate will make the structure form a small bridge which will counteract bending down of the structure.

SHORT FIGURE CAPTION

The invention is illustrated in the attached drawing figures, wherein

FIG. 1 is a section through a portion of a heat exchanger according to the invention with an inlet (or outlet) shown in the left part of the drawing, and wherein the channels extend from a manifold (4 a (5 a)) towards the right. A transparent cover is arranged on top of the heat exchanger, and a frame structure is shown to the left side of the drawing.

FIG. 2 is a simplified section through a first and a second plate of the heat exchanger, wherein channels are formed between those two arc-shaped sections of the first and the second plate.

FIG. 3 shows a plane view and details of a mould for the first plate.

FIG. 4 shows a plane view and details of a casting mould for the second plate.

FIG. 5 is a simplified section through the first, second, and a third plate of a combined heat exchanger embodiment of the invention.

FIGS. 6 a and 6 b are photographic images of an embodiment of the invention wherein the generally parallel longitudinally directed channels (7) are separated by continuous joints (8) preferably comprising many laterally directed arcs or kinks relative to their main axis in the longitudinal direction. The channels (7) are wavy or zigzag-shaped.

DESCRIPTION OF THE EMBODIMENT OF THE INVENTION

The invention is a heat exchanger of the plate type, please see FIG. 1, provided with an internal fluid passage for water or other liquid, comprising a first and a second plate (2, 3) whereof at least the first of the plates (2) is arranged to be exposed to a warmer or colder medium. The fluid may be water or another liquid such as antifreeze solution with a high heat capacity. An antifreeze solution will be advantageous in case of outdoor use in a climate with a risk of temperatures below zero degrees Celsius. The internal passage (6) between the two plates (2, 3) is constrained by manifolds (4 a, 5 a) to an inlet (4) and an outlet (5) for the fluid. The passage (6) forms a widening between the inlet (4) and outlet (5) in that it branches into several channels (7). The internal passage (6) is constrained between those two generally parallel plates (2, 3) and wherein the first and the second plate (2, 3) are formed in a structurally self-supporting polymer material.

In an advantageous embodiment there is arranged an inlet manifold (4 a) between said inlet (4) and said channels (7). Between said channels (7) and said outlet (5) is and is an outlet manifold (4 b), please see FIGS. 6 a and 6 b, and FIG. 1.

The passage is subdivided into a number of generally parallelly directed longitudinal channels (7) separated by continuous junctions (8) between two plates (2, 3) please see FIG. 2. The longitudinal channels extend between the inlet (4) and outlet (5). The longitudinal channels have an arc-shaped cross-section. This will significantly increase the surface area of the exposed plate and thereby increase the heat transmission. The arc-shape of the plates (2, 3) in the channels (7) are to the same face side relative to the plate in order to reduce the volume of fluid residing inside the channels (7). This enhances the ratio between the exposed area and the volume of the present fluid significantly, increasing the heat exchanger's efficiency relative to the volume it occupies. In a advantageous embodiment of the invention, the exposed plate (2) is formed in a heat conductive material which increases the efficiency if the heat exchanger is used for example as a “sunlight collector”.

In an advantageous embodiment of the invention the second plate (3) is thermally insulated in order to reduce heat loss if the heat exchanger shall increase the temperature of the through flowing liquid or to control the heat loss only to one side of the heat exchanger, if it is a wall installed radiator for heating in a house.

According to an embodiment of the invention, the second plate (3) is formed in a thermally conductive material. This is to increase the heat loss if the heat exchanger is used for reducing the temperature of the flowing through liquid, for example, used as a cooler, or used in a tank or in the ground to heat up the surroundings.

In an advantageous embodiment of the invention the generally parallel longitudinally directed channels (7) are separated by continuous joints (8) preferably comprising many laterally directed arcs or kinks relative to their main axis in the longitudinal direction, i.e. that the channels (7) are wavy or zigzag-shaped, please see the drawings of moulds for the formation of the first and the second plates shown respectively in FIG. 3 and FIG. 4. This embodiment is shown in FIGS. 6 a and 6 b. In a preferred embodiment, the moulds are vacuum moulds. The feature of the continuous joints (8) between those two plates (2, 3) in a long zig-zag pattern at either sides of each channel (7) will result in a long joint length and thus a large joint area between the two plates (2, 3). This will allow a liquid pressure of more than 5 Bar before delaminating.

The moulds are in an embodiment of the invention made by cutting the mould using a computer controlled milling machine. The milling cutter may be run at intervals of 0.5 mm resulting in a slightly corrugated surface of the mould. This slightly corrugated surface of the mould results in that the longitudinally extending channels (7) have a corrugated surface generally across the longitudinal direction. This creates microturbulence in the through flowing fluid.

In an embodiment of the invention, one of the plates (2, 3) may have a surrounding rim (10) formed as a self-supporting structural frame (11). This frame may be arranged for bracketing of the plates (2, 3) and for constituting an independent, self supporting structure or for being installed in a building structure. The surrounding rim (10) will provide a more precise positioning of the plates (2, 3) relative to each other so as for obtaining the desired shape of the channels (7).

In a preferred embodiment, e.g. for mounting on a roof as part of a solar collector, at least the first of the plates (2) is covered by a transparent cover (12). The transparent cover (12) may be of glass. In a preferred embodiment of the invention it may be formed of toughened glass, preferably of low iron content. It is important that the transparent cover has little absorption of solar radiation. The transparent cover (12) may alternatively be formed of a polymer material such as polycarbonate, PET (polyethylene teraphthalate), acrylic or a similar transparent polymer material.

In a preferred embodiment of the invention the polymer material of the first and second plate (2, 3) is ABS, polypropylene, PET, or epoxy. This is because these materials are easy to vacuum form. They also have a low weight and low price.

It may be advantageous that the first plate (2) has a high thermal conductivity. Therefore, the polymer material in at least the first plate (2) preferably comprises carbon or CNT (carbon nanotube) reinforced polymer material. This is also to increase the mechanical strength. For carbon reinforcement in the polymer one may use carbonized bamboo particles which are strongly absorbing for infrared radiation and also thermally conductive.

The heat exchanger according to the invention may also comprise a second passage (16) for a second fluid between a second inlet (24) and a second outlet (25) which are formed by arranging a third plate (17) below the second plate (3), wherein the second passage (16) is subdivided into a number of generally parallelly directed longitudinal second channels (18) extending along the first elongated channels (7), separated by continuous joints (19) between the second and the third plate (2 , 3) and extending along the continuous joints (8). Thus there a liquid-liquid heat exchanger is formed. Such an embodiment is indicated in a cross-section in FIG. 5. In an advantageous embodiment according to the invention, the heat exchanger is arranged as a counter flow heat exchanger, ie, the first inlet (4) is near the second outlet (25), and the first outlet (5) is by the second inlet (24).

In an advantageous embodiment according to the invention, please see FIG. 5, the second channels (18) are formed to have an arc-shaped cross-section corresponding to the cross section of the first channels (7), in that the third plate (17) is curved towards the same face as the second and the first plates (2, 3). In this embodiment it would be a significant advantage if the plate (3) is formed in a heat conductive material. The material of the plate (3) may be added CNT or other heat conductivity increasing additives.

In an advantageous embodiment of the invention, low notches (9) are made in one or both of the moulds, please see FIG. 4, so as for forming generally low, inward protruding transverse notches (19) in part of the channels' (7) cross-sections, please see FIG. 2. Such formed low notches (19) in the channels will form constrictions which will redirect part of the liquid flow around them and create more turbulence. This turbulence will counteract laminar flow of the liquid and generally increase the heat transfer from the walls (2, 3) to the liquid, or vice versa.

If used as a heat exchanger under the waterline on a boat hull, one or both of the plates (2, 3) are preferably covered by an antifouling agent. 

1. A heat exchanger of a structurally self-supporting plate type and provided with an internal flow passage constrained between a first and a second plate and extending between an inlet and an outlet, wherein said flow passage is subdivided in multiple generally parallel directed longitudinally extending channels, said longitudinally extending channels having continuous joints formed by said two plates, said longitudinally extending channels having an arch-shaped cross-section, wherein said arch-shape of said plates of said channels is in the same face direction orthogonal to said plates, wherein said parallel running longitudinally extending channels comprise several laterally directed arches relative to their main axis in their longitudinal extension.
 2. The heat exchanger according to claim 1, wherein the second plate is thermally insulated.
 3. The heat exchanger according to claim 2, wherein said second plate is formed in a thermally insulating material.
 4. The heat exchanger according to claim 2, wherein said second plate is formed in a thermally conductive material.
 5. The heat exchanger according to claim 1, wherein said continuous joints comprise many laterally directed kinks relative to their main axis measured in their longitudinal direction.
 6. The heat exchanger according to claim 1, wherein said longitudinally directed channels have a corrugated surface generally across said longitudinal direction.
 7. The heat exchanger according to claim 1, wherein one of said plates has a surrounding rim formed as a self-supporting structural frame.
 8. The heat exchanger according to claim 1, wherein at least said first of said plates is covered by a transparent cover.
 9. The heat exchanger according to claim 8, wherein said transparent cover is glass, preferably toughened glass with low iron content.
 10. The heat exchanger according to claim 1, wherein said transparent cover is made in a polymer material such as polycarbonate, polyethylene teraftalate, acrylic, or similar.
 11. The heat exchanger according to claims claim 1, wherein said polymer material in said first and second plate is ABS, polypropylene, PET, or epoxy.
 12. The heat exchanger according to any of the preceding claims claim 1, wherein said polymer material in at least said first plate is carbon fiber or carbon nanotube-reinforced.
 13. The heat exchanger according to claim 12, wherein said carbon fibre reinforcement in said polymer material comprises carbonized bamboo particles.
 14. The heat exchanger according to claim 1, wherein a second passage for a second fluid from a second inlet and a second outlet is formed by arranging a third plate below the second plate, wherein the second passage is subdivided into a number of generally parallelly directed longitudinal second channels extending along the first longitudinal channels, separated by continuous joints between the second and the third plate and extends along the continuous joints.
 15. The heat exchanger according to claim 14, wherein it is arranged counter flow, i.e. the first inlet is by the second outlet, and the first outlet is by said second inlet.
 16. The heat exchanger according to claim 14, wherein said second channels have a arc-shaped cross-section corresponding to said cross section of the first channels, in that said third plate is curved to the same side as said second and the first plate.
 17. The heat exchanger according to claim 1, wherein the exposed plate is formed of a heat conductive material.
 18. The heat exchanger according to claim 1, further provided with low, inward protruding generally transverse notches in part of the channels' cross-sections.
 19. The heat exchanger according to any of the preceding claims claim 1, wherein between said inlet and said channels is an inlet manifold and between said channels and said outlet is an outlet manifold. 